Method for fabricating a non-inflammable horizontal output transformer

ABSTRACT

A method for fabricating a non-imflammable horizontal output transformer includes: winding a coil member on a hollow insular support; affixing an arcuate ring member to the coil member; surrounding the coil member, ring member, and leads and the coil member with an envelope of fire-proof material; and assembling said coil member onto a pair of U-shaped core members positionally held by a U-shaped wire member.

Unite States Patent [1 1 Arrington et al.

[ METHOD FOR FABRICATING A NON-INFLAMMABLE HORIZONTAL OUTPUT TRANSFORMER [76] Inventors: William Lee Arrington; Wayne Carlton Gantt, both of Batavia;

.Leonard Joseph Gouger, Albion, all

of NY.

[22] Filed: Mar. 9, 1972 [21] Appl. No.: 233,047

Related US. Application Data [62] Division of Ser. No. 113,463, Feb. 8, 1971, Pat. No.

[52] US. Cl 29/605, 29/602, 336/96, 336/192, 336/205, 336/210 [51] lnt.-Cl. H01f 7/06 [58] Field of Search 29/602, 605, 630 B; 336/96, 192, 205, 208, 210, 197

[56] References Cited UNITED STATES PATENTS 3,533,036 10/1970 Wood 336/96 [111 3,766,643 1 Oct. 23, 1973 2,731,607 l/1956 Gould et al. 336/96 1,768,950 7/1930 Frank 336/197 X 3,227,981 l/l966 Krepps, Jr. et al. 336/192 2,782,283 2/1957 Schwennesen 29/630 B UX 3,408,605 10/1968 Hughes et al. 336/96 2,956,250 10/1960 Harse 336/210 X 3,569,885 3/1971 Hilgers 336/96 Primary Examiner-Charles W. Lanham Assistant Examiner-Carl E. Hall Attorney-Norman J. OMalley et al.

[57] ABSTRACT A method for fabricating a non-imflammable horizontal output transformer includes: winding a coil member on a hollow insular support; affixing an arcuate ring member to the coil member; surrounding the coil member, ring member, and leads and the coil member with an envelope of fire-proof material; and assembling said coil member onto a pair of U-shaped core members positionally held by a U-shaped wire memher.

3 Claims, 3 Drawing Figures METHOD FOR FABRICATING A NON-INFLAMMABLE HORIZONTAL OUTPUT TRANSFORMER CROSS-REFERENCE TO RELATED APPLICATION BACKGROUND OF THE INVENTION Color television receivers utilize a horizontal output transformer to effect coupling of horizontal sweep signals from a horizontal output stage to deflection apparatus associated with a cathode ray tube. Also, the horizontal output transformer effects development of high voltage potentials for application to the electron beam accelerating electrodes of a cathode ray tube. Moreover, the horizontal output transformer provides focus potentials for the cathode ray tube as well as flyback potentials, AGC keyer potentials, blanking potentials and numerous other ancillary potentials and functions.

Normally, horizontal output transformers of the prior art include a coil form of electrical insulating material whereon primary and auxillary windings are located. A high voltage winding surrounds and is affixed by adhesive or in some similar manner to the primary and auxillary windings. Also, the high voltage winding is surrounded by a corona tire of non-inflammable material either prior to or after attachment thereof to the primary and auxillary windings.

Following, the coil form is telescoped over a pair of confronting leg members of a pair of substantially U- shaped core members and positionally held thereon by wedges, adhesive, or some similar technique. Also, leads exiting from the coil are electrically insulated in some manner and affixed to a circuit board attached to the U-shaped core members. A U-shaped wire member affixes the U-shaped core membersto a support.

Although the above-mentioned horizontal output transformers have been and still are widely employed in television receivers, it has been found that there is something to be desired insofar as economy and efficiency is concerned. More specifically, it has been found that positionally locating the coil on the core member by wedges and similar techniques and adding formed on a hollow insulator telescoped over a pair of confronting leg members of a pair of U-shaped core members. An arcuate ring member is affixed to the coil member and has a plurality of contact pins connectable to a plurality of leads extending outwardly from the coil insulators to wires for attachment thereof to a circuit board leaves much to be desired insofar as efficiency of construction and time is concerned. Moreover, exposed leads and circuit board connections are incompatible to enhanced non-inflammable construction.

OBJECTS AND SUMMARY OF THE INVENTION An object of the present invention is to provide an enhanced horizontal output transformer for a television receiver. Another object of the invention is to provide improved electrical coupling for a horizontal output transformer. Still another object of the invention is to provide improved indexing and attachment of a coil form to a core member of a horizontal output transformer. A further object of the invention is to provide a horizontal output transformer of improved fire-proof characteristics. A still further object of the invention is to provide an improved process for fabricating horizontal output transformers.

These and other objects, advantages and capabilities are achieved in one aspect of the invention by a horizontal output transformer having a coil member with an envelope of non-inflammable material surrounding the coil member, core member, and leads.

The horizontal output transformer is fabricated by a process which includes winding a wire coil member with indicating markers therein, affixing an arcuate ring member having contact pins therein to the coil member, selecting wires of the coil member indicated by the markers and affixing a wire to a contact pin of the ring member, wax impregnating the coil member, encapsulating the coil member, selected wires, and ring members, and assembling the coil member and a pair of U-shaped core members.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a portion of the horizontal output transformer wherein a ring member with contact pins therein is affixed to a coil member.

FIG. 2 illustrates, in exploded form, a preferred horizontal output transformer embodiment; and

FIG. 3 is a cross-sectional view of FIG. 2 taken along the lines 3-3.

DESCRIPTION OF A PREFERRED EMBODIMENT For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure in conjunction with the appended claims and accompanying drawings.

Referring to FIG. 1 of the drawings, a preferred form of horizontal output transformer includes a coil member 5 wound on a hollow insulator 6 and having a plurality of wire leads 7 extending outwardly therefrom. A substantially arcuate ring member 9 having a plurality of slotted contact pins 11 therein is affixed to the periphery of the coil member 5. Moreover, each of the wire leads 7 is connected to at least one of the contact pins 11.

As to fabrication of a horizontal output transformer, the coil member 5 is wound on the hollow insulator 6 with a plurality of wire indicating markers included within the winding. The wires located at each of the wire markers are selected to provide wire leads 7 extending outwardly from the coil member 5.

A substantially arcuate ring member 9 is pressure fitted to the periphery of the coil member 5. Also, the ring member 9 includes a plurality of contact pins 11, which are preferably'of the slotted variety to permit attaching the wire leads without wrapping. Each one of the wire leads 7 is affixed to at least one of the contact pins 11. Obviously, the contact pins 11 may be of a variety other than slotted and the wire leads 7 may be attached thereto by soldering, welding, or any one of a number of well-known attaching techniques.

The coil member 5 is impregnated with any one of a number of well-known fire-resistant waxes, such as Wax No. 'G5945 for instance, available from the Biwax Co., Des Plaines, Illinois. The wax impregnated coil members 5, wire leads 7, and ring member 9 are surrounded with an envelope, 13 of FIG. 2, of noni-nflammable material. For example, one well-known non-inflammable material is known as a vinyl epoxy thermosetting resin referred to as RL-095-l6 and manufactured by the Michell-Rand Manufacturing Corporation of Hillburn, New York. Moreover, numerous non-inflammable materials in the form of vinyl epoxy resins are readily available and attainable on the commercial market.

Referring to the exploded view of FIG. 2, the envelope 13 surrounding the coil member includes an indenture l5 and an arc resisting indented circle 16 formed therein. A pair of U-shaped core members 17 and 19 each have a pair of leg members, 21 and 23 and 25 and 27 respectively, which are spacedby a pair of interconnecting members 29 and 31.

The coil member 5 with the envelope l3 thereon is telescoped over a pair of confronting leg members 23 and 27 of the U-shaped core members 17 and 19. The indenture is formed for cooperative engagement with an interconnecting member 31 of the U-shaped core member 19 and disposed intermediate the pair of interconnecting members 29 and 31.

Thereafter, a substantially U-shaped wire member 33, having a protuberance 35 therein, is fitted into grooves 37 and 39 extending along the leg members 21, 23, 25, and 27 of the U-shaped core members 17 and 19. The U-shaped wire member 33 extends through a support member 41 and is affixed by a pair of nuts 43 and 45. Moreover, the protuberance 35 of the wire member 33 exerts a pressure intermediate the hollow insulator 6 of the core member 5 and the U-shaped core members Hand 19. Thus, the indenture 15 as well as the protuberance 35 tend to maintain the core member 5 in a fixed rotational position with respect to the core members 17 and 19.

As can be seen in the cross-sectional view of FIG. 3, taken along the line 33 of FIG. 2, the coil member 5 with the affixed ring member 9 having the outwardly extending contact pins 11 and covered by an envelope 13 of non-inflammable material is telescoped over confronting leg members 23 and 27 of the U-shaped core members 17 and 19. The core members 17 and 19 are positionally held by the U-shaped wire member 33 and the coil'member 5 is rotationally held by the pressure intermediate the indentation 15 of the envelope 13 and one of the core members 19 and by the pressure intermediate the protuberance 35 of the U-shaped wire member 33 and the core member 5. V

Thus, there has been provided a unique horizontal output transformer suitable for use in television receivers. The transformer includes a coil member totally en closed in'an envelope of non-inflammable material as well as'greatly enhanced lead connection capabilities. Moreover, the structure also features improved techniques for achieving and maintaining rotational stability of a coil member with respect to the core members of a transformer.

Further, the transformer is fabricated by an improved process having'numerous advantages over other known techniques. The process is economical of both time and operator labor due to the improved cooperation between the indented envelope and core members. Moreover, the fabrication process is attainable at a speed and cost believed to be unattainable by other known techniques.

While'there has been shown and described what is at present considered the preferred embodiment of the invention, it will be understood that various changes and modifications may be made therein without departing from the invention as defined by the appended claims.

What is claimed is:

1; A horizontal output transformer fabricating process comprising in combination:

' winding a coil member on a hollow insulator support with wire indicating markers therein; affixing a substantially arcuate ring member having contact pins therein to the periphery of the coil member; selecting wires at said indicating markers and affixing each wire to a contact pin of said ring member; fire-proofing said coil member by impregnation thereof with a fire-resistant wax; fire-proofing said coil member, ring member, and selected wires by encapsulation thereof with an envelope of fire-proof material; and

pressure engaging said hollow insulator support and a protuberance of a U-shaped wire member cou- 'pled to a pair of substantially U-shaped core members to provide an assembled horizontal output transformer.

2. The combination of claim 1 wherein said substantially arcuate ring member is affixed to said coil member by pressure exerted therebetween.

3. The combination of claim 1 wherein said U-shaped wire member includes a protuberance formed for pressure engagement with at least'one of said U-sha'ped core members and said hollow insulator of said coil member. v

and that said Letters Patent are hereby corrected as 522 3 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Potent No. 3,766,643 Dated October 3, 1973 William Lee Arrington, Wayne Carlton Gantt, Leonard Josepn uouger Inventofls) It is certified that error appears in the aboveidentified patent shown below:

Insert [73]. Assignee: GTE SYLVANIA INCORPORATED,

' a corporation of Delaware Signed and sealed this .L th day of June-19714..

(SEAL) Attest EDWARD I I.FLETCHER,JR. C. MARSHALL DANN Attestinp; Officer v Commissioner of Patents,

P04050 7 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION P tent No. 3,766,643 Dated October 1973 Invenmfls) wi lliam Lee Arrington, Wayne Carlton Gantt, Leonard v v Josepn Gouger It'is certified that error appears in the above-identified patent and that: aaid Letters Patent are hereby corrected as shown below:

Insert [73]; Assignee: GTE SYLVANIA INCORPORATED,

' a corporation of Delaware Signed and sealed this rL .t h-' day of June's-1971;.

(SEAL) Attest v EDWARD T/I.FLETCHER,JR. A c. MARSHALL DANN Attestiny-g Officer Commissioner of 'Pzemtentsv 

1. A horizontal output transformer fabricating process comprising in combination: winding a coil member on a hollow insulator support with wire indicating markers therein; affixing a substantially arcuate ring member having contact pins therein to the periphery of the coil member; selecting wires at said indicating markers and affixing each wire to a contact pin of said ring member; fire-proofing said coil member by impregnation thereof with a fire-resistant wax; fire-proofing said coil member, ring member, and selected wires by encapsulation thereof with an envelope of fire-proof material; and pressure engaging said hollow insulator support and a protuberance of a U-shaped wire member coupled to a pair of substantially U-shaped core mEmbers to provide an assembled horizontal output transformer.
 2. The combination of claim 1 wherein said substantially arcuate ring member is affixed to said coil member by pressure exerted therebetween.
 3. The combination of claim 1 wherein said U-shaped wire member includes a protuberance formed for pressure engagement with at least one of said U-shaped core members and said hollow insulator of said coil member. 